Appendix B: Motor Control Troubleshooting

Guide

B. Appendix B: Motor Control Troubleshooting Guide

Trouble Cause Remedy

OVERLOAD RELAYS 1. Sustained overload. 1. Check for grounds,

Tripping shorts, or excessive
motor currents and
correct cause.

2. Loose connection on 2. Clean and tighten.

load wires.

3. Incorrect heater. 3. Heater should be

replaced with one of
correct size.

MAGNETIC AND 1. Broken shading coil. 1. Replace magnet and

MECHANICAL PARTS armature.
Noisy Magnet

2. Magnet faces not 2. Replace magnet and

mating. armature.

3. Dirt or rust on 3. Clean.

magnet faces.

4. Low voltage. 4. Check system

voltage and voltage
dips during starting.

Failure to Pick Up and 1. Low voltage. 1. Check system

Seal voltage and voltage
dips during starting.

2. Coil open or 2. Replace.

shorted.

3. Wrong coil. 3. Replace.

4. Mechanical 4. With power off,

obstruction. check for free
movement of contact
and armature
assembly.

Failure to Drop Out 1. Gummy substance 1. Clean pole faces.

on pole faces.

2. Voltage not 2. Check coil circuit.

removed.

3. Worn or rusted parts 3. Replace parts.

causing binding.

4. Residual magnetism 4. Replace magnet and

due to lack of air gap armature.
in magnet path.

PNEUMATIC TIMERS 1. Foreign matter in 1. Replace timing head

valve. completely or return
timer to factory for
repair and adjustment.

Erratic Timing 1. Maladjustment of 1. Adjust as per

Contacts Do Not actuating screw. instruction in service
Operate bulletin.

2. Worn or broken 2. Replace snap

parts in snap switch. switch.

LIMIT SWITCHES 1. Overtravel of 1. Use resilient

Broken Parts actuator. actuator or operate
within tolerances of
the device.

MANUAL STARTERS 1. Latching mechanism 1. Replace starter.

Failure to Reset worn or broken.

COMPENSATORS 1. Inching, jogging, and 1. Excessive inching

(MANUAL) operating handle and jogging not
Welding of Contacts on slowly. recommended (caution
Starting Side operator); move handle
swiftly and surely to
start position.

Welding of Contacts on 1. Moving handle 1. Move handle swiftly

Running Side slowly to run position. and surely to run
position as motor
approaches full speed.

2. Lack of sufficient 2. Replace contacts

spring pressure. and contact springs.

Damaged or Burned 1. Repeating inching 1. Excessive inching

Transformer and jogging. and jogging not
recommended (caution
operator).

2. Holding handle in 2. Hold handle in start

start position for long position only until
periods. motor approaches full
speed.

CONTACTS Contact 1. Broken shading coil. 1. Replace magnet and

Chatter armature.

2. Poor contact in 2. Replace the contact

control circuit. device or use holding
circuit interlock (three-
wire control).

3. Low voltage. 3. Correct voltage

condition. Check
momentary voltage dip
during starting.

Welding or Freezing 1. Abnormal inrush of 1. Check for grounds,

current. shorts, or excessive
motor load current; or
 use larger contactor.

2. Rapid jogging. 2. Install larger device

rated for jogging
service.

3. Insufficient tip 3. Replace contacts

pressure. and springs, check
contact carrier for
deformation or
damage.

4. Low voltage 4. Correct voltage

preventing magnet condition. Check
from sealing. momentary voltage dip
during starting.

5. Foreign matter 5. Clean contacts with

preventing contacts Freon; contactors,
from closing. starters, and control
accessories used with
very small current or
low voltage should be
cleaned with Freon.

6. Short circuit. 6. Remove short or

fault and check to be
sure fuse or breaker
size is correct.

Short Tip Life or 1. Filing or dressing. 1. Do not file silver

Overheating of Tips tips. Rough spots or
discoloration will not
harm tips or impair
their efficiency.

2. Interrupting 2. Install larger device

excessively high or check for grounds,
currents. shorts, or excessive
motor currents.

3. Excessive jogging. 3. Install larger device

 rated for jogging.

4. Weak tip pressure. 4. Replace contacts

and springs, check
contact carrier for
deformation or
damage.

5. Dirt or foreign 5. Clean contacts with

matter on contact Freon.
surface.

6. Short circuits. 6. Remove short or

fault and check to be
sure fuse or breaker
size is correct.

7. Loose connection. 7. Clean and tighten.

8. Sustained overload. 8. Check for excessive

motor load current or
install larger device.

COILS 1. Mechanical damage. 1. Handle and store

Open Circuit coils carefully.
Roasted Coil

1. Overvoltage or high 1. Check application

ambient temperature. circuit and correct.

2. Incorrect coil. 2. Install correct coil.

3. Shorted turns 3. Replace coil.

caused by mechanical
damage or corrosion.

4. Undervoltage, 4. Correct system

failure of magnet to voltage.
seal in.

5. Dirt or rust on pole 5. Clean pole faces.

faces increasing air
gap.

SOURCE: Courtesy Square D Co.

Citation
EXPORT
Daniel R. Tomal, Ph.D.; Aram S. Agajanian, Ph.D.: Electronic Troubleshooting, Fourth
Edition. Appendix B: Motor Control Troubleshooting Guide, Chapter (McGraw-Hill
Professional, 2014), AccessEngineering

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